Uncut floats over cutting wire, and wire construction



. De cQ l, 1959 J, HARDlNG 2,915,091

UNCUT FLOATS OVER CUTTING WIRE, AND

' WIRE CONSTRUCTION I Filed Sept 9, 1955 2 Sheets-Sheet 1 Dec. 1, 1959 J H, HARDING 2,915,091

I UNCUT FLOATS OVER CUTTING WIRE, AND

WIRE CONSTRUCTION Filed Sept. 9, 1955 2 Sheets-Sheet 2 INVENTOR J in Henry Hafiz Uflitd StflttiS Patent 1...

UNCUT FLOATS OVER CUTTING WIRE, AND WIRE CONSTRUCTION John Henry Harding Masland & Sons, sylvania Philadelphia, Pa., assignor to C. H. Carlisle, Pa., a corporation of Penn- The present invention relates to pile fabrics, of the character of carpets and rugs.

A purpose of the invention is to facilitate production of cut and uncut pile in a pile fabric having pile projectrons of shorter span and pile projections of longer span, for example normal pile and high float pile.

A further purpose is to carry high floats over cutters on wires without being cut while cutting normal pile.

A further purpose is to cause the high floats to jump the cutter at the end of the wire by providing a limited free cutter height, above the maximum height of the Wire Within the shed, so that because of their greater looseness the floats will pass over the cutter without being cut, While the normal pile will be cut by the cutter.

A further purpose is to put in a wire provided with selective cutter means as the second wire to be withdrawn of the wires over which pile warp ends float.

Further purposes appear in. the specification and in the claims.

In the drawings I have chosen to illustrate .a few only of the numerous embodiments in which my inven tion may appear, selecting the forms shown from the standpoints of convenience in illustration, satisfactory operation and clear demonstration of the principles involved.

Figure 1 is a warpwise conventional weave diagram showing a fabric of the invention as woven before withdrawing the wires.

Figure 2 is a diagram corresponding to Figure 1 showing the weave after the wires have been withdrawn.

Figure 3 is a fragmentary diagrammatic perspective of the preferred form of wire employed in weaving according to the invention.

Figure 3a is a view corresponding to Figure 3 showing a variation.

Figures 4, 5 and 6 are views corresponding to Figure 1 showing variations.

Describing in illustration but not in limitation and referring to the drawings:

Extensive use has been made in pile fabrics, especially carpets and rugs, of floats over transverse pile wires. As the floats are controlled by a jacquard, weaving in the Brussels or Wilton manner, it is possible and rather common to employ floats intermingled with normal pile, or to employ short and long high floats.

It will be evident that in normal pile the pile remains in the face of the fabric above the wire for a relatively short distance. In traditional carpet weaving the normal pile projection is bound behind the next binding weft, whereas in staggered pile two-frame weaving the pile projection remains up in the face of the fabric over only one binding weft. In either case the span of the pile projection is short, the length of yarn in the pile projection is correspondingly limitedand the freedom of the pile projection to stretch is reduced by the short section of the backing which must be flexed, the short section of pile yarn which is free to stretch, and the fact that ines ecially 2. herently the pile projection is of an elongated float.

On the other hand, where the pile projection floats over two or more wires, or where it is carried over one wire and remains floating under the next wire or under a series of adjoining wires and is then boundin the back of the fabric, the pile projection naturally is higher and also is more resilient and less tight.

Efforts have been made in the prior art to'produce cut'and uncut effects in pile-fabrics having floats by using combinations of cuttingand noncutting wires andcarrying the floats under the cutting wires if they remain floating at a particular point. This has the disadvantage, however, of limiting the design and'it is impossible to produce cut and uncut pile in the same transverse row by weaving over a single wire in the prior art.

I have discovered that the effect of obtaining cut and uncut pile projections in the same transverse row in a fabric using short and long span pile, such as normal pile and float pile, can be obtained by using special wires, aloneor in combination with other wires.

In accordance with the invention, weaving is carried on in the conventional manner except that the wires inserted are selective cutters. The effect then is, when the wire is withdrawn, especially when it is Withdrawn by the usual wire mechanism at high speed, to cause the floats or the long span pile projections to jump the cutter and not be cut, while the normal pile or the short span pile projections encounter the cutter and are cut.

The effective height of the cutter is limited, as by making the cutter so low that it will cut the short span but not the long span pile projections, or by making the cutter effectively low due to a jump projection ahead of the cutter.

Considering first the form of Figures 1 to 3, I there illustrate two frames of pile warp ends 20 and Z1, binder warp ends 22 and 23, stutter warp ends 24, upper wefts 25 and lower weft 26 woven together in any suitable carpet weave or any other pile fabric weave.

of lower height than that As shownin Figure 1, in the first step the pile warp.

ends 20 are raised, binder warp ends 22 are raised half way, and all other ends are lowered, forming a lower shed. The raising of the pile warp ends has been vdetermined by the jacquard mechanism. A weft 25 .is 1

inserted in the lower shed.

In the second step pile warp ends 20 and 21 arefully raised and binder warp ends 22 and .stutfer warp ends 24 are raised half way forming an upper shed, as determined by the jacquard mechanism, and binder warp ends 23 are lowered forming a lower shed. A wire 27 according to the invention is inserted in the upper shed and a weft 26 is inserted in the lower shed. For convenience in. illustration in the diagram, the wire is shown by a conventional illustration of a cutting wire with an X above to indicate that it is a special cutting wire as later explained.

In the third step as shown, pile warp ends 21 areraised as determined by the jacquard, pile Warp ends v 20 are lowered as determined by the jacquard and binder warp ends 23 are raised half way, while all other warp ends are lowered, forming a lower shed. A shot of weft 25 is inserted in .the shed.

In the fourth step, pile warp ends 20 and 21 are fully raised, as determined by the jacquard,binder warp ends 23 and stuifer warps 24 are raised halfway forming an upper shed, and binder warp ends 22 are lowered, forming a lower shed. A wire 27 is inserted in them;- per shed and a shot of'weft 26 is inserted in the lower shed.

The essential weaving technique above described is Patented Dec. 1, 1959' followed in successive steps, except that the jacquard mechanism in the formation of each upper shed where a wire is inserted and in the formation of the next shed determines whether the particular pile warp ends are to form high floats, to form normal pile or to be rejected. Thus Figure 1 illustrates a high float or long span pile projection 28 of one of the pile warp ends 21 which is up over two wires and over one upper weft and then bound behind upper wefts on either side. Subsequently the same pile warp ends 21 form short span pile projections 30 which are up over single wires and are bound behind upper wefts on either side.

The pile warp ends 20 behave similarly and form high floats or long span pile projections 31 similar to the high floats 28 but in staggered relation thereto and short span pile projections 32 similar to the short span pile projection 30 but in staggered relation thereto.

Thus there will be woven over the same transverse pile wire at a particular longitudinal position high floats which may be called long span pile projections and normal pile or short span pile projections.

Figure 3 shows one form of wire 27 according to the invention, having at the end remote from the head (not shown) a cutter 29 so limited in maximum height that it will not develop enough tension in long span pile projections to cut them, but will cut short span pile projections. Good results have been obtained using a razor blade set in a recess of the wire and extending up diagonally from a point level with the top of the wire at the forward end to a point 0.040 inch above the top of the wire at the maximum point near the rear end of the cutter as shown. The exact maximum height of the cutter will vary in difierent looms, but is of this order of magnitude.

In the form of Figure 3a, the wire 27 is provided at the far end remote from the head (not shown) with a jump projection 33 protruding up above the normal maximum top level 34 of the wire within the shed. This jump projection 33 has a gradually upwardly curving approach portion 35 and a gradually receding trailing portion 36 and is generally smooth, free from burrs and adapted to stretch the pile projections without cutting.

Immediately behind the trailing portion 36 of the jump abutment 33 is a cutter 37 which desirably extends up diagonally and has a sharp cutting blade 38 angularly disposed in the direction of withdrawal of the wire which is indicated by the arrow 40. While the cutter 38 is shown as being part of the wire, it will be evident that the question of whether the cutter 38 is part of the wire or is a separate insert such as a razor blade is immaterial from the standpoint of the present invention.

The relative heights of the jump abutment and cutter in the form of Figure 3a should be of the same order of magnitude. The cutter should not protrude markedly above the jump projection to such an extent that it will firmly encounter and cut all ends passing over the'jump projection. The intention is that the jump projection will raise all of the ends and that the pull-down by the short span pile projections will be rapid and will cause these projections to be cut, while the pull-down of the long span pile projections will not be rapid and the cutter will not cut long span projections. Of course, in the form of Figure 3a the cutter may be higher above the wire than in the form of Figure 3.

When the wires are pulled out successively, the result achieved is as shown in Figure 2. The long span pile projections or floats 28 and 31 remain uncut. The pile projections 30 have been cut into tufts 30 and 3t] and the pile projections 32 have been cut into tufts 32' and 32 It will be evident that in accordance with the design there will be floats 28 and 31 and also short span pile projections 30 or 32 which will be in the same transverse row, so that the effect is to produce cut short span pile 4 and uncut long span pile in the same transverse row and woven over the same pile wire.

It will of course be evident that by variation in thread-in, considerable changes can be accomplished to suit the requirements of the particular weave, and it is not material from the standpoint of the present invention whether the pile warp ends 20 and 21 as shown in Figures 1 and 2 are in the same dents or in alternate dents.

it will also be evident that the principles of the invention can be applied in combination with other features well known in the weaving art. Thus it is immaterial from the standpoint of the invention whether the wires according to the present invention as shown in Figure 3 or 3a constitute the complete wire set or whether they are alternated or interspersed with wires of different character such as straight wires, wavy or serrated wires, cutting wires, noncutting wires, flag wires, high or low wires, narrow or thick wires, or wires having two or more of these characteristics in a single wire. Likewise the principles of the present invention can be combined with other features present on the wire 27. Thus while the wire 27 is shown as a straight wire, it will be evident that it can be used as part of a combination as of high and low wires, thick and thin wires, or wavy wires and it can if desired have a wavy upper surface, although in this case the maximum height within the shed will desirably be substantially less than the height of the jump abutment 33.

There may, in individual cases, be an advantage in using a wire of a different type as the first wire within the float to be pulled so as to further loosen the float before the wire 27 of Figure 3 or 3a is pulled, thus further assuring against the possibility of unintended cutting of the float.

It will be of course be evident that any of a wide variety of jacquard mechanisms may be used to produce the floats, although I prefer to use a mechanism conforming to my US. Patent No. 2,649,862, granted August 25, 1953, for Jacquard Mechanism and Process.

It will of course be evident that wide variations in the weave construction can be made, it being unimportant from the standpoint of the present invention whether single or double binder warps are used, or whether single or multiple stufier warps are employed.

Likewise it is unimportant from the standpoint of the present invention whether the weave is bound behind binding upper wefts or whether the weave is a throughto-the-back weave bound behind lower binding wefts.

In Figure 4 I illustrate a two-frame weave in which the pile warp ends are bound behind lower binding wefts as well known.

' It is also unimportant from the standpoint of the present invention whether the floats are floats for example over two wires or over three or more wires. In Figure 4 I illustrate floats 41 and 42 each over three wires which functionas long span pile projections and remain uncut when the wires are withdrawn, and I also illustrate normal pile projections 43 and 44 which will be cut when the wires are withdrawn to form tufts in the same transverse rows as the floats.

While in Figures 1 and 4 high floats are shown, inter-- mediate floats may be used, and these are illustrated in Figure 5. Thus in Figure 5, pile end 21 is shown in a float 45, which is over two wires and then remains in the face of the fabric at 46 above the next weft before it is bound in the back. There is also shown an intermediate float 47 of pile warp end 20 which is in the face of the fabric above one weft and then over one wire and weft. These floats remain uncut when the wires are withdrawn while the normal pile projection 30 of this fabric is cut.

It is immaterial from the standpoint of the present invention whether the subject matter is carried out in multiple frames as shown in Figures 1, 4 and 5, or in a single frame. Figure 6 illustrates a single frame jacquard weave which has floats 31 over two wires and normalpile projections 32, In the course of the weave, as the 5 pattern requires, these will appear in the same transverse row and when the wire 27 is withdrawn there will be cutting of the short span pile projections but not cutting of the long span floats.

In view of my invention and disclosures, variations and modifications to meet individual whim or particular need will doubtless become evident to others skilled in the art, to obtain all or part of the benefits of my invention Without copying the structure, method and weave shown, and I, therefore, claim all such insofar as they fall within the reasonable spirit and scope of my claims.

Having thus described my invention, what I claim as new and desire to secure by Letters Patent is:

1. A pile wire having a head, having a body which extends through the shed, and having at the end of the wire beyond the shed remote from the head a jumping oflf place above the height of the body of the wire and cutter means above the height of the body of the wire located immediately behind the jumping ofi place with respect to the head, said cutter means not extending substantially above the jumping off place, said jumping 01f place holding the ends up and releasing them ahead of the cutter means, said cutter means cutting the ends of high tension and passing the ends of low tension uncut.

2. A pile wire having a head, having a body connected to the head and extending through the shed, forming a shed portion of the pile wire, and having on the body beyond the shed at the end remote from the head a jump projection above the level of the top of the body, and cutter means beyond the jump projection extending above the top of the body, the jump projection having an approach curvature and a drop-cit before the cutter means is encountered.

References Citedin the file of this patent UNITED STATES PATENTS 760,985 Hardwick May 24, 1904 763,181 Hardwick June 21, 1904 1,885,137 Pickard Nov. 1, 1932 2,030,763 Pickard et a1 Feb. 11, 1936 2,285,332 Gebert June 2, 1942 2,600,241 Hamilton June 10, 1952 2,681,083 Dacey June 15, 1954 2,685,894 Parlin Aug. 10, 1954 2,695,634 Miller et al. Nov. 30, 1954 2,700,401 Smiley Jan. 25, 1955 

